Apparatus for embossing of materials with high-frequency vibrations

ABSTRACT

A workpiece which is to have a raised pattern applied to at least one surface thereof is positioned in the apparatus between a support member and a die member, the surface of the die member being a reverse image of the desired pattern. While the die member and workpiece are held in contact by a static force, highfrequency vibrations are applied to impress the pattern on at least one surface of the workpiece. Several alternate embodiments involve rotating dies or relative movement between the source of vibrations and the die and workpiece in a plane perpendicular to the direction of the high-frequency vibrations.

0 United States Patent {151 695,669 Balamutli 1 Wan. W 1999 [54]APPARATUS FOR EMBOSSING 0F 2,414,177 1/1947 Smith ..l8/19 A ux MATERIALSWITH HIGH-FREQUENCY 2,815,535 12/1957 Bodine ..25/41 I X NATIONS 533321?311323 lff" aif/ 2)? 0 me Inventor: Lewis Balflmuth, Washington Square3,146,492 9/1964 Lemelson IE/l0 was, New York, 3,283,378 11/1966Cramton.... ..18 10 x 73 Assignee; Gavin-on Corporation, Long Island,3,298,065 l/l967 Pendleton ..264/23 X [22] Fl d J I 26 1968 3,323,4466/1967 Alpini ..l8/l6 F X 1 e u y 2 APPL 1 0 3 Primary ExEa;ninerC.}l).Howard Flint, Jr.

Attorney win earson Related [1.8. Application Data [63] Continuation 0fSer. NO $72,064, Aug. 12, 1966, [57] ABSTRACT abandoned- A workpiecewhich is to have a raised. pattern applied to at least one surfacethereof is positioned in the apparatus [52] U.S. Cl ..425/3, 264/23,425/299, between a support member and a die member, the surface f425/303 425/385 425/396 the die member being a reverse image of thedesired pattern. [5 1] lift. Cl t While the die member and workpiece areheld in Contact y a Fleld of Search M, F, 10, A, static force, g fi. q yvibrations are to impress 18/17 264/23 25/41 72/56 the pattern on atleast one surface of the workpiece. Several 453 alternate embodimentsinvolve rotating dies or relative move- 5 6] References Cited mentbetween the source of vibrations and the die and workpiece in a planeperpendicular to the direction of the high- UNITED STATES PATENTSfrequency vibrationsl,954,635 4/1934 Leonard l8/l0 112 Claims, 11Drawing Figures JZ? fi GENERATOR mam m s m sum 1 BF 2 FIG.

GENERATOR Zfi III/4 INVENTOR LEWIS BALAMUTH ATTORNEY PAYENTED m 1 8 m23.635609 sum 2 0F 2 F/GS jay/ F/Gf Zz F466 INVENTOR LEWIS I BALAMUTHZWWLW.

ATTORNEY APPARATUS FOR EMBOSSING OF MATERIALS WITH HIGH-FREQUENCYVIBRATIONS This application is a continuation of application Ser. No.572,064, filed Aug. l2, 1966 and now abandoned.

This invention relates generally to an improved apparatus for impressinglow relief patterns into a wide variety of materials and moreparticularly, is directed to embossing a work member or the like,employing high-frequency, preferably ultrasonic vibrations for theembossing operation.

in general, embossing consists in applying forces which cause thematerial of the work member, to be shaped, to flow into preformed diesurfaces ofa die member whereby a replica of the die pattern in reverseis produced. In this way, not only continuous patterns of repeatingdesign may be formed, but also individual cameo or intaglio forms ofgreat beauty reproduced.

The primary object of the invention is to provide improved apparatus forthe embossing of materials.

A further object of the invention is to provide improved apparatus forthe embossing of materials utilizing ultrasonic energy.

Another object of the present invention is to provide improved apparatusto emboss a variety of materials at pressures and temperatures muchreduced as compared with known embossing techniques.

Yet another object of the invention is to provide improved apparatus forintroducing high-frequency vibratory energy in the deformable materialof the work member so that the desired flow occurs due in part toacoustic softening action.

A further object of the invention is to provide improved apparatus toemboss materials at greatly reduced static forces.

Still yet a further object of the present invention is to provideimproved apparatus to emboss more delicate sheet materials with muchdeeper intaglio or cameo detail.

Still another object of the present invention is to provide improvedapparatus to emboss materials with configurations not of a continuousdesign.

it has been established in the prior art that high-frequency mechanicalvibrations do, in fact, soften both metals and plastics. The softeningeffect in plastics and other materials is described and used in U.S.Pat. No. 3,184,353, issued May 18, 1965, assigned to the assignee of thepresent invention and in which the present inventor is a coinventor. Inthe case of metals, the work of Langenecker, as discussed in the reportof B. Langenecker et al., entitled Effects of Ultrasound on DeformationCharacteristics of Structural Metals," U.S. Naval Ordinance TestStation, China Lake, Cal., NAVWEPS Report 8482, Mar. I964, has shownthat metals ranging from alu minum to tungsten and including steel andcopper, may be rendered plastic by the introduction of ultrasonicvibratory energy alone.

The present applicant has appreciated and pioneered in this work, andhas enumerated as a general principle, what may be called the principleof thermal equivalence." This principle asserts that when a phenomenonis produced primarily by the use of high temperature and heat transfer,then the same phenomenon may be produced by the use of highfrequencymechanical vibrations applied at reduced temperatures. This principlehas found many uses in ultrasonics including metal and plastic weldingand joining procedures.

Moreover, the applicant has not discovered that the principles ofacoustically softening materials with high-frequency mechanicalvibrations may be employed in a new and novel way to obtain theultrasonic embossing of materials in ac cordance with the presentinvention, and hereinafter described in greater detail.

in accordance with the present invention, the work member to be embossedis supported in overlapping relationship with a die member having atextured surface, a replica of which is to be reproduced on the surfaceof the work member. On the opposite side of the work member, the sideremote from the die member, the work member is generally supported on asupport or backup member so as to apply a static force to the sandwichedwork member. The static force is applied in a direction to urge the workand die members against each other into complete continuous interfacialcontact. High-frequency mechanical vibrations are simultaneouslytransmitted to the work member at a predetermined frequency ofvibration, which is preferably approximately in the range of l kcJsec.and kc./sec., so as to transmit compressional waves to the interface ofthe die and work member to effect a softening of the work member incontact with the textured die surface. This softening results in theflow of material into the impre sions of the die member under thecontinuous static force. in this manner, a replica of the texturedsurface of the die member is formed in the work member.

in accordance with another aspect of the invention, for cer tainembossing operations the die and work members are moved relative to eachother along a predetermined path to obtain the desired replica of thetextured surface on the work member. If the work member is of anextended length and the embossed design of a shallow depth, then therelative movement between the die and work members is in a planeparallel to the area of overlap. if the depressions of the die surfacesare of a more substantial depth then they may be moved in a planetowards each other a controlled distance to obtain a reproduction of thedie surface in the work member.

In accordance with one aspect of the present invention, thehigh-frequency mechanical vibrations may be transmitted to theinterfacial area of the die and work members by means of any elasticallyconducting path. For example, the vibratory energy may be transmitteddirectly to the die member, which is preferably constructed of amaterial having favorable transmission qualities, so that the acousticalwaves are transmitted therethrough to the textured die surface.Accordingly, if the material, which may be in either sheet fon'n or arigid body, to be embossed is a common thermoplastic such as styrene orthe like, the compressional waves may be transmitted through theplastic. For the transmission of the elastic waves through the plastic,the support member itself may form the source of vibratory energy as bybeing coupled to an ultrasonic vibratory assembly.

It is preferable to use compressional ellastic waves which willpropogate readily through either the die: or the plastic, so that thevibration may be applied either through the plastic, to the die memberor through the die member to the plastic, depending on convenience ofoperation. On the other hand if the thermoplastic is of the air-cellexpanded type, it is not a good transmitter of elastic wave energy, andso it is preferable in such cases to transmit the energy through the diemember, to the thermoplastic body.

ln accordance with another aspect of the invention, it is possible byadjusting the frequency and amplitude of vibration, that the apparatuscan be used to emboss a variety of materials with a variety ofconfigurations. it is desirable that the interfacial area be situatedgenerally at a loop of compressional waves in the plane substantiallynormal to the die sur face. In this manner, the principle of thermalequivalence may be employed so as to accentuate the softeningcharacteristics of a plastic body when subjected to high-frequencymechanical vibrations and the surface softened to flow into the valleysof the die surface.

Additionally, the work surface to be embossed may be situatedsubstantially at a node of vibration where the stresses are greater tofurther enhance the softening of the work member.

The term ultrasonic as used herein is intended to include acousticvibrations, for example, at a frequency in the range betweenapproximately 1 kc./sec. and 100 kc./sec. The operating frequency may bein the higher sonic or ultrasonic ranges, preferably in the rangebetween approximately l5 kc./sec. and 30 kc./sec.

The above, and the other objects, features and advantages of theinvention, will be apparent in the following detailed description ofillustrative embodiments thereof which is to be read in connection withthe accompanying drawings forming a part hereof, and herein:

FIG. l is a front view of an ultrasonic apparatus according to theinvention for embossing a work member;

FIG. 2 is a side view, partly in section, of the ultrasonic embossingapparatus of FIG. I;

FIG. 3 shows, at enlarged scale, the relationship of the die and workmembers of FIG. 1, during the embossing operation;

FIG. 4 is a view similar to FIG. 3 showing a different arrangement ofthe tool, die and work members;

FIGS. 5 and 6 are fragmentary front and side views respectively, butshowing another embodiment of the invention wherein the vibratory energyis transmitted to both sides of the work member;

FIGS. 7 and 8 are fragmentary front and side views respectively, butshowing another embodiment of the invention, wherein the work member isrotated along the surface of the die member;

FIG. 9 is a view similar to FIG. 7, but illustrating another embodimentof the present invention;

FIG. 10 is a side view, partly schematic of an ultrasonic embossingapparatus, illustrating another embodiment of the invention, andgenerally used for continuous embossing operations; and

FIG. 11 is a sectional view taken along the line 11-11 of FIG. 10.

Similar reference characters refer to similar parts throughout theseveral views of the drawings and specification.

Referring to the drawings in detail, and initially to FIGS. 1 and 2thereof, there is illustrated apparatus 10 for ultrasonically embossinga work member 100. As indicated by the crosshatching in FIG. 1, the workmember 100 is of a plastic material, but it will be realized that rigidbodies or sheets of materials such as metal, glass, paper, wood, etc.,may be embossed in accordance with the present invention. However, forthe purpose of the explanation of the figures to follow, it will beassumed that the apparatus is working with plastic materials.

The basic structure for embossing materials comprises a vibrator supportassembly in the form of a support stand 15 that is provided formaintaining the vibrator assembly 25 in proper position, and may includea base 16 with an upright wall 17 extending upwardly from one end ofsaid base and a head 18 extending from the upright wall 17 and inoverlapping relationship to the base 16. Mounted on the upright wall 17is a mounting channel 19 which engages a support block 20 which isslidably connected by a dovetail connection (not shown) to the mountingmember 19 to permit vertical movement of the vibrator assembly betweenthe base 16 and head 18 of the support stand 15. The vibrator assembly25 is suitably secured to the support block 20, for example, by means ofbands 26 which encompass the casing 27 of the vibrator assembly and aresecured to the support block 20 by means of bolts 28. A support memberor mounting fixture 22 of any suitable type for holding the work member100 is provided on the base 16 and has a recess 23 therein for receivingthe work member.

Drive means 29 to effect vertical movement of the vibrator assembly 25toward and away from the support member 22 is provided and may be in theform of a cylinder 30 vertically mounted to the head 18 and having ashaft 31 extending therefrom and through the head 18 and coupled to ahorizontal flange 21 of the support block 20 in any conventional manner.The air cylinder 30 may be operated by supplying compressed air conveyedby a conduit 32 from an exterior source (not shown) and extended fromthe rear of the cylinder. The exact height of adjustment is generallydetermined prior to the commencement of the embossing cycle and willdetermine the depth of the textured surface.

The mechanical vibrator assembly 25 includes a transducer (not shown)which may be any one of a number of electromechanical types, such as,electrodynamic, piezoelectric or magnetostrictive. The operatingfrequency may be in the sonic or ultrasonic range between approximatelyI kc./sec. to I00 kc./sec. but preferably in the range from l5 kc./sec.to 30 kc./sec. The vibrator assembly 25 is preferably of the typegenerally disclosed in the U.S. Pat. No. RE 25,033 issued Aug.

29, I961. The transducer 35 housed within the casing 27 may be cooled asby water or air.

The vibrator assembly 25, generally includes a driver unit made up of atransducer secured to an acoustic impedance transformer or tool 36 thatextends from the casing 27. The transducer of mechanical vibrations maycomprise a stack of laminations of magnetostrictive material, forexample, nickel, and surrounded by a coil winding (not shown) adapted tocarry a biased, high-frequency alternating energizing current. The lowerends of the laminations making up the stack of the transducer arefixedly secured, as by welding or soldering, to the upper end of thetransformer 36. The transformer 36 has an enlarged section (not shown)in the general area of a nodal plane of motion, and this sectionconstitutes a flange secured to the casing 27.

A biased, high-frequency alternating current is supplied to the windingthrough conductors 38 extending from a suitable oscillation generator40, which may be of the type disclosed at page 270 of UltrasonicEngineering," by Alan B. Crawford, published 1955 by ButterworthScientific Publications, London. An oscillation generator of this typeis effective to supply a biased alternating current to the winding at aresonant frequency of the driver unit of transducer and is furthereffective to vary the frequency of the supplied biased, alternatingcurrent when the resonant frequency of the driver unit is varied due tochanges in temperature, or changes in the loading thereof. Although thefrequency of the supplied biased, alternating current is adjusted, inthe oscillation generator disclosed in the above identified publication,in response to a feedback signal from a capacitor-type pickup connectedin the transducer, it is to be understood that other types of pickupsmay be employed. Other existing types of oscillation generators may alsobe employed, for example, as disclosed in U.S. Pat. No. 2,872,578, inwhich adjustment of the frequency of the alternating current supplied bythe oscillation generator is obtained through the use of a feedbacksignal which varies with the impedance of the transducer.

The lower or output end 37 of tool 36 is coupled to the input end 47 ofdie member 45 so that when the vibrator assembly 25 is operated, byelectrical oscillations supplied from generator 40, compressional wavesare generated in the stack of laminations, the tool 36 and die member45, so as to cause vibrational movements in the vertical direction, thatis along the longitudinal axis of the transducer. For the purposes ofthe present invention, such vibrations preferably have a frequency inthe range between approximately 1,000 cycles per second and 100,000cycles per second, and are of sizable amplitude, for example, in therange between approximately 0.0001 and 0.01 inch. In order to ensurethat the maximum amplitude of vibration in the vertical direction isobtained at the lower end or textured die surface 48 of the die member45, as indicated by the double headed arrow 46, thus ensuring themaximum transmission of working acoustical energy, the overall length ofthe stack of magnetostrictive laminations, the tool 36, and the diemember 45 is selected so that, at the frequency of the electricaloscillations supplied to winding of the transducer, a loop oflongitudinal motion of the generated compressional waves occurs at ornear the die surface 48 of the die member 45.

The die member 45 as seen in FIGS. 1 and 2 is of a metallic materialhaving good acoustical transmission properties so that the vibrationstransmitted from the input surface 47 are propogated through the memberto its output die surface 48. The coupling between the output end 37 ofthe vibrator assembly 25 and the die member 45 may be of anyconventional form for example as by a threaded coupling (not shown). Ifthe static force applied between the output end 37 of the tool 36 andthe input surface 47 of the die member 46 is of sufficient magnitudethen no mechanical coupling between the two is required.

The output surface 48 of the die member 46 may have any number ofdesired configurations so that a replica of the die surface is embossedon the work member which is generally of a plastic material. As seen inFIG. 3, which is an enlarged view showing the interfacial contact areabetween the die member 46 and the work member I00 to more clearlyillustrate the workings of the present invention, the output surface 48has a textured surface which consists of a series of valleys 49 andpeaks or hills 50 that when blended together with various radii, form adesired surface configuration which is to be reproduced in the plasticmember. When the work member 100 is of a rigid plastic body and one sidethereof is to be embossed, then the material displaced will flow intothe valleys or voids 49 of the textured die surface 48. In a rigidplastic body or sheet of material the material displaced is made to flowdue to the acoustical softening characteristics when high-frequencymechanical vibrations are transmitted to the surface 101 of the workmember 100. It is preferable that the volume of material displaced inthe work member is substantially equal to the voids or cavities withinthe textured die surface 48. In this manner, the embossed surface of theplastic member is formed and the stresses minimized by supplyingsufficient room for the displaced material to flow, expand and contract.

To commence the embossing operation the work member 100 is seated withinthe support member 22' wherein the lower surface 102 of the work memberrests in the recess 23. The die member 45 is then brought intooverlapping relationship with the work member 100 so that the textureddie surface 48 engages the upper surface 101 of the work member.

To obtain this position, the vibratory assembly 25 is verticallyadjusted by means of the drive means 29. The cylinder drive 30 isenergized and the shaft 31 extending therefrom vertically adjusts theheight of the vibrating assembly through its coupling with bracket 20.While in this position, the oscillator generator 40 is energized tosupply current so as to induce high-frequency mechanical vibrations inthe transducer that are transmitted through the tool 36 and die 45 tothe die surface 48. These high-frequency vibratory motions which aregenerally in the range of l kc./sec. to I00 kc./sec. are applied in aplane substantially normal to the surface 101 of the work member 100.The vibratory die member 45 is maintained in energy-transferringrelationship to the work under a static force for retaining the die andwork member in complete continuous interfacial contact. If the diesurface has a substantial depth, then the static force is continuallyapplied to obtain relative movement towards each other until a completereplica of the configuration of said textured die surface 48 is formedin said work member. As the energy is transmitted to this interfacialarea, a gradual softening of the generally The die member 45a which hasa preformed textured surface 48a also acts as a part of the supportmeans and is seated within the receiving recess 23a of the supportmember 22a. The support member 45a has a peripheral rim 53 which is provided to retain the die member 45a in place prior to and during theapplication of the high-frequency vibrations. The die member 45a in turnmay be provided with an annular rim 52 to retain the work member inposition. As seen in FIG. 4, the work member 100a is of a rigid plasticmaterial, such as styrene which is a good transmitter of high-frequencyvibrations, and as indicated by the arrows 46a the vibrations aretransmitted through the plastic work member 100a to the interface of thedie and work members. For those applications, where it is desirable thatthe vibrations are coupled directly to the work member this form of thepresent invention may be employed and it has been found that the:ultrasonic embossing techniques herein illustrated may be carried out inthis manner.

FIGS. 5 and 6 illustrate another embodiment of the present invention 10bwherein it is desired to continually emboss a particular configurationon an extended work member 1001) which is either in sheet form or of arigid body. The die member 45b is maintained in fixed spacedrelationship to a cooperating support member 22b, which has at its lowersurface coupled thereto a separate tool 36b which also produceslongitudinal vibrations, as indicated by arrows 46b, in the supportmember. The die surface 48b is comprised of a series of valleys 49b andhills 50b which when blended together form a pattern which is to bereproduced on work member 10Gb. The cooperating support member 22b hascorresponding valleys 54 and hills 55 formed in its output surface 51 tomesh with those of the textured die surface 48b. The work member 10% isprogressively moved along a fixed path relative to the die and supportmembers, in the direction of arrow 56. In this manner, the embosseddesign is continually obtained on both plastic work member 100 occurs inaccordance with the general principle of thermal equivalence and as thissoftening and resultant flow of material continues, the verticalmovement of the drive means 29 is continually energized so as tocontinuously form the desired shape of the textured die sur face in thework member.

For plastic materials the interfacial area between the die and workmembers is preferably maintained at a loop of compressional waves in theplane substantially normal to the die surface. When the material beingembossed is of a metallic material or other material requiringadditional concentrations of energy at the interfacial area thetransducer and die member combination may be designed whereas the diesur face is substantially at a node of compressional waves in the planesubstantially normal to the die surface in accordance with the teachingsof applicants copending application Ser. No. 52l,949 filed Dec. 15, I965and assigned to the present assignee. The selection of placing the workmember at a loop of nodal region is primarily dependent upon thematerial it is composed of and the depth of the embossed design.

FIG. 4 illustrates another form 10a of the present invention which isessentially similar to theapparatus shown in the embodiment illustratedin FIGS. 1 through 3, except that the high-frequency mechanicalvibrations are transmitted from the output end 37a of the tool 36adirectly to the work member 100a.

sides of the work member.

In vibrating two dies simultaneously it is possible to further reducethe static forces required and obtain at the work site greater quantityof vibratory energy to further enhance the embossing operation.

FIGS. 7 and 8 illustrate another embodiment of the present inventionwherein the die member is maintained in a stationary position and alsoacts as a support member for the work member l00c that is to beembossed. The die member 450 may be in the form of an elongated membersupported within a rectangular frame 57. The die member 450 ispreferably made of a metal and is physically held within the frame 57 bya plurality of set screws 58 threaded through the frame 57 to engage thedie member of 450.

The die member 450 is set into ultrasonic vibration by a plurality ofvibrator assemblies which are shown coupled via their tool 360 to thedie member. This arrangement of supporting and driving an elongatedmember is discussed in U.S. Pat. No. 3,] 13,225. The work member 100C isin the form ofa cylinder that may be a printing roller used inprocessing a future product, or it may be a manufactured item, forexample, a wheel as used on toy automobiles. The work member 1000 issupported on shaft 59 which is rotated in the direction of arrow 60 byconventional means not shown herein. The work member 10C is rolled alongthe die surface 480 under a static force so that the textured surface ofthe die member may be formed on the periphery I04 thereof. As the workmember is rotated the peaks 50c and valleys 49c of the die surface dficare embossed onto the peripheral surface 104 of the work member to formcorresponding peaks hill and depressions 62 which may have any number ofdesigns.

FIG. 9 illustrates another embodiment 10d of the present in ventionwherein the work member 100d may be in either sheet form or of a rigidmaterial which is to be embossed on one surface thereof. The die member45d has a series of valleys 49d and hills 5011 which when combinedtogether fon'n the textured surface 48d, a replica of which surface isto be embossed on the work member 100d. In this embodiment the diemember also acts as part of the support means during the embossingoperation and the high-frequency vibrations, as indicated by arrow 46d,are transmitted directly to the plastic member and through which memberthe mechanical vibrations are transmitted to the interfacial contactarea between the die member and work member.

In operation, the work member 100d is placed in overlapping relationshipto the die member 45d, which may be of an elongated form, and the outputend 37d of the tool 36d is maintained under a static force against thesurface 102d while the opposite side thereof 101d engages the diesurface 48d. As the work member and die members are maintained inoverlapping relationship the tool 36d is moved across the surface 102dof the work member and the mechanical vibrations 46d are transmitted tothe overlapping area. The vibrations progressively effect a softening ofthe work member to cause it to conform to the surface configuration ofthe die member 45d under the static force. A series of projections 63are gradually formed on the work member as the vibratory member 36d ismoved along a plane substantially parallel to the textured surface 48din the direction as indicated by arrow 64. In this manner the embosseddesign is formed on the work member.

FIGS. 10 and 11 illustrate another form 102 of the present invention,similar to the embodiment illustrated in FIGS. and 6, for use generallywhen high-speed embossing opera- =tions of a continuous design aredesired to be performed on sheets or rigid webs, and the embossing isperformed on one or both sides of the work member. In order that thetextured surface be continuously applied to the work member 100e, a pairof rollers 65 and 66 respectively, are employed.

Roller 65 is comprised of an annular die member 45e in the form of aring having the textured surface 48e on its outer peripheral surfacethereof. The inner surface 47e is coupled to a radially vibratingmechanical assembly 25e (FIG. The opposite roller 66 may have acorrespondingly fonned surface so that the work member l00e may beembossed on both sides thereof. As seen schematically in FIG. 10, therollers are mounted on shafts 67 and 68 respectively, which aresupported by sideplates 69 that may have ball bearings therein to permitrotation of the shafts 67 and 68. The rollers are maintained in fixedspaced relationship to each other to form a nip or region having aspacing therebetween which is generally equal to or less than thethickness of the work member 1002 in the plane substantially normal tothe direction of travel of the work member as it is progressively movedalong a predetermined path in the direction of arrow 70. As the workmember is advanced, it is fed between the peripheral surfaces of therollers, one of which is simultaneously vibrated in a radial mode and atan ultrasonic frequency. Applicants copending application Ser. No.464,594 filed May 18, 1965, may be referred to for one means ofobtaining the desired radial mo- The radial vibrator is comprised of avibrator assembly 25e having its tool (not shown) extending therefromand coupled to shaft 67. The shaft is provided with a hub 71substantially at a nodal region of longitudinal motion wherein theradial motion as indicated by the arrows 72 in FIG. 10 is a maximum.Thus vibratory energy is transmitted to the ring shaped die member 452causing it to vibrate radially and transmit these vibrations in a planesubstantially normal to the die surface 48e. The textured peripheralsurface is mounted in rolling contact with the work member 1002 so thatmechanical vibrations are transmitted in a direction substantiallynormal to the movement of the work member along its predetermined path.In this manner, a replica of the contoured configuration of the diemember is formed in the work member. The support member or roller mayalso have a textured surface that may be complimentary to that of thedie member and rotated at the same angular speed as indicated by arrows73 so that the valleys 49e and hills 50e of the die member will coincidewith the valleys 74 and hills 75 of the support member whereby bothsurfaces may be simultaneously embossed with the same or differentdesigns.

Gears 76 and 77 are mounted on shafts 67 and 68 respectively and motor78 is secured to end plate 69 and energized in any conventional mannerto drive the support member 66, which in turn through the gears theroller 65 is driven.

By employing high-frequency vibratory energy in an embossing process, inaccordance with the methods herein, the applicant has found that thestatic forces required to normally form the embossed surfaces on a workmember are substantially reduced. The reason for this reduction is thatpressure alone is no longer accountable for the displacement of thematerial into the embossed configuration. The ability to soften materialby employing acoustical energy also permits the embossing of a greatervariety of materials at substantially reduced pressures than heretoforepossible with the prior art methods. With the present invention, it isalso possible to emboss materials in sheet form that are substantiallythinner and of a more fragile material as well.

Additionally, the depth of the embossed configuration on a thin sheetmay be greater since the static forces are reduced and there is lesschance of the sheet tearing under the static forces involved. Inaddition, the acoustical softening principle may be applied to bothplastic and metals as well, so that it is also possible to embossmetalic materials on one or both sides thereof with fine embossed linesat reduced static forces.

Although illustrative embodiments of the invention have been describedin detail herein with reference to the accompanying drawings, it is tobe understood that the invention is not limited to those preciseembodiments, and that various changes and modifications in addition tothose mentioned above may be effected therein by one skilled in the artwithout departing from the scope or spirit of the invention, except asdefined in the appended claims.

I claim: 1. Apparatus for embossing a relatively solid work member,comprising means for supporting the work member, a die member having atextured surface, a static force means for urging the textured surfaceof said die member against said work member, and

high-frequency vibratory means operatively coupled to said static forcemeans for embossing a replica of said textured surface onto said workmember, the frequency being between approximate l kc./sec. and kc./sec.

2. Apparatus for embossing a relatively solid work member, comprising, i

an electromechanical transducer vibratory means for supplyinghigh-frequency vibrations in the range of l kc./sec.

to I00 kc./sec., said vibratory means further including an outputsurface having a textured surface thereon, and a static force means forurging the textured surface of said output surface against said workmember for embossing a replica of said textured surface onto said workmember. 3. Apparatus for embossing a relatively solid work member as inclaim 2, wherein said static force means includes a mounting means fordisplacing said vibratory means relative to the work member.

4. Apparatus for embossing a relatively solid work member as in claim 1,wherein the high-frequency vibratory means includes an electromechanicaltransducer which vibrates in a direction substantially perpendicular tothe plane of the textured surface.

5. Apparatus for embossing a relatively solid work member as in claim 1,wherein said support means includes said die member.

6. Apparatus for embossing a relatively solid work member as in claim 1further including a means for providing relative movement between saidwork member and said die member resulting in continuous embossing.

7. Apparatus for embossing a relatively solid work member as in claim 1,wherein said support means also has a textured surface so that bothsides of the work member may be simultaneously embossed.

8. Apparatus for embossing a relatively solid work member as in claim 2,wherein said output surface is in a generally circular form, and saidvibratory means is coupled to said output surface to cause a radialvibration further including a means for rotating said output surface asthe output surface engages said work member.

9. Apparatus for embossing a relatively solid work member as in claim 1further including a means for effecting movement of the vibratory meansrelative to the die member and work member in a plane perpendicular tothe direction of the vibratory motion.

10. Apparatus for embossing a relatively solid work member as in claim9, wherein the movement means causes the die

1. Apparatus for embossing a relatively solid work member, comprisingmeans for supporting the work member, a die member having a texturedsurface, a static force means for urging the textured surface of saiddie member against said work member, and high-frequency vibratory meansoperatively coupled to said static force means for embossing a replicaof said textured surface onto said work member, the frequency beingbetween approximate 1 kc./sec. and 100 kc./sec.
 2. Apparatus forembossing a relatively solid work member, comprising, anelectromechanical transducer vibratory means for supplyinghigh-frequency vibrations in the range of 1 kc./sec. to 100 kc./sec.,said vibratory means further including an output surface having atextured surface thereon, and a static force means for urging thetextured surface of said output surface against said work member forembossing a replica of said textured surface onto said work member. 3.Apparatus for embossing a relatively solid work member as in claim 2,wherein said static force means includes a mounting means for displacingsaid vibratory means relative to the work member.
 4. Apparatus forembossing a relatively solid work member as in claim 1, wherein thehigh-frequency vibratory means includes an electromechanical transducerwhich vibrates in a direction substantially perpendicular to the planeof the textured surface.
 5. Apparatus for embossing a relatively solidwork member as in claim 1, wherein said support means includes said diemember.
 6. Apparatus for embossing a relatively solid work member as inclaim 1 further including a means for providing relative movementbetween said work member and said die member resulting in continuousembossing.
 7. Apparatus for embossing a relatively solid work member asin claim 1, wherein said support means also has a textured surface sothat both sides of the work member may be simultaneously embossed. 8.Apparatus for embossing a relatively solid work member as in claim 2,wherein said output surface is in a generally circular form, and saidvibratory means is coupled to said output surface to cause a radialvibration further including a means for rotating said output surface asthe output surface engages said work member.
 9. Apparatus for embossinga relatively solid work member as in claim 1 further including a meansfor effecting movement of the vibratory means relative to the die memberand work member in a plane perpendicular tO the direction of thevibratory motion.
 10. Apparatus for embossing a relatively solid workmember as in claim 9, wherein the movement means causes the die memberand work member to move conjointly relative to the vibratory means. 11.Apparatus for embossing a relatively solid work member as in claim 2,further including a means for effecting movement of the vibratory meansrelative to the output surface and work member in a plane perpendicularto the direction of the vibratory motion.
 12. Apparatus for embossing arelatively solid work member as in claim 11, wherein the movement meanscauses the output surface and work member to move conjointly relative tothe vibratory means.